HANDBOOK SAFETY DEVICES. Ed SAFETY DEVICES DS-ED 01/ ENG 1

Transcription

1 HANDBOOK Ed DS-ED 01/ ENG 1

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3 INDEX CHAPTER 1 Safety valves in series 3030 CHAPTER 2 Safety valves in series 3060 CHAPTER 3 Safety valves in series 3061 CHAPTER 4 Safety valves in series CHAPTER 5 CHAPTER 6 Selection criteria for safety valves Changeover valves in series 3032, 3032N, and 3032E CHAPTER 7 Fittings in series CHAPTER 8 Shut-off valves in series 3064, 3064N, and 3064E 47 CHAPTER 9 Bursting disc devices in series 3070 CHAPTER 10 Fusible plugs in series 3080 and THE NATURAL DEVELOPMENT OF QUALITY Having achieved the goal of fifty-five years working in the Refrigeration and Air Conditioning Industry, Castel s range of quality products is well known and highly appreciated around the world. Quality is the product of our Company philosophy and marks every step of the production cycle. It is certified by the company s Quality Management System (certified by TUV SUD in accordance with the UNI EN ISO 9001:2008 standard), as well as by the various product certifications of compliance with European Directives and European and extra-european Quality Marks. Product quality is connected with the quality of manufacturing. We produce on high-tech machinery and updated automatic production lines, operating in compliance with the current safety and environmental protection standards. Castel offers the Refrigeration and Air Conditioning Market and Manufacturers tested certified products suitable for use with the HCF and HFO refrigerants currently used in the Refrigeration & Air Conditioning Industry. Based on the experience gained in the refrigeration field using fluorinated fluids, Castel is proud to present the Refrigeration and Air Conditioning Market and Manufacturers two complete lines of products developed and proven for use in systems using natural refrigerants: hydrocarbons (HC fluids) and carbon dioxide (R744). DS-ED 01/ ENG 3

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5 Directive 2014/68/EU issued of the European Parliament and of the Council of 15 May 2014 on pressure equipment Directive 2014/68/EU (PED Recast) applies to the design, manufacture and evaluation of compliance of pressure equipment and assemblies with a maximum allowable pressure, PS, greater than 0.5 bar excluding the cases listed in Article 1, Paragraph 2 of the Directive. Directive 2014/68/EU was transposed into the Italian legal system by Legislative Decree No. 26 dated 15 February 2016, published in the Official Journal of the Republic of Italy No. 53 of 4 March The revised PED Recast Directive repeals previous Directive 97/23/EC. More specifically: Article 13 of the PED Recast Directive, regarding the classification of pressure equipment, came into force as of 1 June 2015 and repeals Article 9 of the previous PED Directive. All other articles of the PED Recast Directive are in force as of 19 July 2016, repealing all articles of the previous PED directive. All safety valves, bursting disc devices and fusible plugs illustrated in this technical handbook are considered Safety Accessories according to the definition provided in Article 2, Point 4 of said Directive and are subject to the classification indicated in Article 4, Point 1.d) of the same Directive. All valves illustrated in this technical handbook are considered Pressure Accessories according to the definition provided in Article 2, Point 5 of said Directive and are subject to the classification indicated in Article 4, Points 1.c) and 3 of the same Directive. external leakage All the products illustrated in this Handbook are submitted, one by one, to tightness tests as well as specific functional tests. The allowable external leakage, measurable during the test, complies with the requirements of standards: EN : 2003 Refrigerating systems and heat pumps - Valves - Requirements, testing and marking EN : 2011 Refrigerating systems and heat pumps - Qualification of tightness of components and joints Pressure containment All the products illustrated in this Handbook, if submitted to hydrostatic testing, guarantee a pressure strength at least equal to 1.43 x PS in compliance with Directive 2014/68/EU. All the products illustrated in this Handbook, if submitted to burst test, guarantee a pressure strength at least equal to 3 x PS according to EN : 2016 Standard. Weight The weights of the items listed in this Handbook include packaging and are not binding. Warranty All Castel products are covered by a 12-month warranty. This warranty covers all products or parts thereof that turn out to be defective within the warranty period. In this case, at his own expenses, the customer shall return the defective item with a detailed description of the claimed defects. The warranty does not apply if the defect of the Castel product is due to mistakes by the customer or by third parties, such as incorrect installation, use contrary to Castel instructions, or tampering. In the event of defects found in its products, Castel will only replace the defective goods and will not refund damages of any kind. Castel reserves the right to make changes or modifications to its products at any time without prior notice. The products listed in this handbook are protected according to law. DS-ED 01/ ENG 5

6 CHAPTER 1 SAFETY VALVES IN SERIES 3030 tightness on the valve seat. The gasket is made from PTFE (Polytetrafluorethylene), a material that, during the valve s estimated service life, maintains good strength and does not cause the shutter to stick on the seat. The shutter is properly guided in the head and the guide action cannot fail. There are no glands or retaining rings that hamper its movement. Material used: EN CW614N brass Spring: it opposes the pressure and the fluid dynamic forces, and always ensures closing of the valve following pressure relief. When the shutter has reached the maximum height determined by the mechanical stop, the spring compression does not exceed 85% of the total compression. Material used: DIN steel for springs. GENERAL DESCRIPTION The valves in series 3030 are unbalanced, conventional direct-loaded safety valves. The valve is opened by the thrust from the fluid under pressure below the shutter, when said thrust exceeds, under the calibrated conditions, the opposing force of the spring acting on the shutter. Valves are identified by means of: a model number formed of an alphanumerical code that includes: the family identity (for ex. 3030/44) the type of connection (C = ; G = Gas) the set pressure, expressed in bar, multiplied by 10 (for ex. 250) An alphanumerical serial number CONSTRUCTION Body: squared, obtained through hot moulding and subsequent machining. It houses the following elements: the nozzle with flat sealing seat the shutter guide the set spring slot the threaded seat of the setting adjustment ring nut In the body, above the shutter guide, a small pressure relief hole is provided through which the spring slot communicates with the atmosphere. For this reason, during relief, there is a gas leak through this orifice. Material used: EN CW617N brass Shutter: obtained through machining from bar stock and fit with gasket, it ensures the required degree of Calibration system: hex-head threaded ring nut to be screwed inside the upper portion of the head, compressing the spring below. When calibration is complete, the position of the ring nut is maintained unchanged by applying to the threaded coupling a high mechanical strength and low viscosity bonding agent. The low viscosity promotes penetration. The calibration system is protected against subsequent tampering by means of a threaded cap nut, screwed on outside the head and sealed with a Castel lead seal. SCOPE Use: protection against possible overpressure of the apparatuses listed below, with regard to the operating conditions for which they have been designed: Refrigeration system or heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, or piping. (reference standard: EN 378-2:2016) Simple pressure vessels (reference Directive: 2009/105/EC) Fluids: the valves in series 3030 can be used with: a. Refrigerant fluids in vapour or gaseous state belonging to Group 2: HCFC (R22) HFC (R134a, R404A, R407C, R410A, R507) HFO and HFO/HFC mixtures (R1234ze, R448A, R449A, R450A, and R452A) R744 with reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC Regulation No. 1272/2008). b. Air and nitrogen (reference Directive: 2009/105/EC) 6 DS-ED 01/ ENG

7 For specific applications with refrigerant fluids not listed above, please contact Castel Technical Department. MARKING In compliance with the provisions of Article 19 of Directive 2014/68/EC, the following information is reported on the valve body: Manufacturer s mark Country of manufacturing Indication of flow direction Maximum allowable pressure CE marking Identification number of the notified body involved in the production control phase Again, on the body, the following information is laser marked: Valve model Serial number Set pressure Temperature range allowed Kd discharge coefficient Flow section Production date DOCUMENTATION The safety valves in series 3030 are supplied with the following documentation provided in the packaging: operating instructions for the user, containing all information useful for safety in terms of assembly, commissioning, use, and maintenance. Compliance Statement for the equipment according to Directive 2014/68/EU, required in Article 17 and issued in compliance with Annex IV of the same directive. Calibration certificate for the safety valve, printed on the reverse side of the Compliance Statement. N.B.: on the website: use the Certifications pull-down menu to access the web-page Castel Certification Download Center. On this page, you can download: the Compliance Statement / Calibration Certificate for each valve by entering the 7-digit alphanumeric serial number. the general Compliance Statement referring to a specific model of valve 3030 with a specific setting, for ex. 3030/44C250 or 3030/88C420. VALVE SELECTION Directive 2014/68/EC requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the maximum allowable pressure (PS) of the equipment they protect. In any case, a short pressure peak limited to 10% of maximum allowable pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific product and sector standards listed below: EN ISO : 2013: Safety devices for protection against excessive pressure Part 1: Safety valves indicates the general requirements for safety valves regardless of the fluid for which they were designed. EN 378-2:2016: Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation provides a general outline of the protection devices to be used in refrigerating systems and their characteristics (Para ) and the criteria for the selection of the device suitable for the type and size of the system component to be protected (Para ). EN 13136:2013: Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and provides users with the tools for sizing pressure relief devices, among which safety valves. select the safety valves in series 3030, please see Chapter 5 Selection Criteria for Safety Valves in this technical handbook. Tables 3 and 4 provide the maximum discharge capacities of safety valves, models 3030/44 and 3030/88, as a function of various refrigerants and varying P set for the valve, considering T o = Steam saturation temperature at discharge pressure, P o. VALVE INSTALLATION Safety valves type 3030 guarantee repeatable performance. This means that, after the valves have operated, open/close, the initial setting conditions are maintained. Nevertheless, it is advisable to replace a 3030 valve once it has discharged as during release debris, such as metal shavings or solder impurities, can deposit on the valve gasket. This can inhibit the safety valve from returning to its original conditions. calculate the pressure loss in either the upstream line (between vessel and safety valve) or the downstream line (between safety valve and atmosphere) refer to Chapter 5 Selection Criteria for Safety Valves in this technical handbook. DS-ED 01/ ENG 7

8 TABLE 1: General Characteristics of valves 3030 Catalogue Number 3030/44C 3030/44G 3030/66C 3030/88C Connections Inlet male 1/2" 1/2" G 3/4" 1" Outlet male 3/4" G 3/4" G 3/4" G 1.1/4" G Inlet connection wrench torque (min/max) [Nm] 21/30 21/30 32/45 50/65 Flow Diameter [mm] ,5 Flow Section [mm 2 ] Lift [mm] 4,1 4,1 4,1 6,8 Discharge Coefficient "Kd" 0,90 0,90 0,90 0,83 PS [bar] 55 TS - 50 / TA - 40 / + 50 Set Pressure Range at atmospheric back pressure Pset [bar] Overpressure Blowdown Helium tightness Estimated service life Risk Category according to PED Recast 9 / % of Pset - 15 % of Pset 85 % di Pset (9 bar < Pset < 31 bar) 90 % di Pset (31,1 bar < Pset < 50 bar) 5 years IV Catalogue Number TABLE 2: Dimensions and Weights of valves 3030 Dimensions [mm] Ø D L Ch H 1 H 2 H 3 Weight [g] 3030/44C /44G /66C /88C DS-ED 01/ ENG

9 Pset [bar] Po [barsass] TABLE 3: Maximum discharge capacity of valves 3030/44 ; 3030/66 R134a R22 R404A R407C R410A R448A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , ,0 45,0 90, , , ,0 46,1 92, , , ,0 47,2 93, , ,0 48,3 94, , ,0 49,4 95, ,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued DS-ED 01/ ENG 9

10 Pset [bar] Po [barsass] TABLE 3: Maximum discharge capacity of valves 3030/44 ; 3030/66 R449A R450A R452A R507 R1234ze R744 (CO2) 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , , ,0 35,1 71, , , , , , ,0 36,2 73, , , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, , ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 10 DS-ED 01/ ENG

11 Pset [bar] Po [barsass] TABLE 4: Maximum discharge capacity of valves 3030/88 R134a R22 R404A R407C R410A R448A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , ,0 45,0 90, , , ,0 46,1 92, , , ,0 47,2 93, , ,0 48,3 94, , ,0 49,4 95, ,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued DS-ED 01/ ENG 11

12 Pset [bar] Po [barsass] TABLE 4: Maximum discharge capacity of valves 3030/88 R449A R450A R452A R507 R1234ze R744 (CO2) 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , , ,0 35,1 71, , , , , , ,0 36,2 73, , , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, , ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 12 DS-ED 01/ ENG

13 CHAPTER 2 SAFETY VALVES IN SERIES 3060 tightness on the valve seat. The gasket is made from PTFE (Polytetrafluorethylene), a material that, during the valve s estimated service life, maintains good strength and does not cause the shutter to stick on the seat. The shutter is properly guided in the body and the guide action cannot fail. There are no glands or retaining rings that hamper its movement. Material used: EN CW614N brass Spring: it opposes the pressure and the fluid dynamic forces, and always ensures closing of the valve following pressure relief. Material used: DIN steel for springs. Calibration system: hex-head threaded ring nut to be screwed inside the upper portion of the body, compressing the spring below. When calibration is complete, the position of the ring nut is maintained unchanged by applying to the threaded coupling a high mechanical strength and low viscosity bonding agent. The low viscosity promotes penetration. The calibration system is protected against subsequent tampering by means of a threaded cap nut, screwed on outside the brass body and blocked in place through re-flanging. GENERAL DESCRIPTION The valves in series 3060 are unbalanced, conventional direct-loaded safety valves. The valve is opened by the thrust from the fluid under pressure below the shutter, when said thrust exceeds, under the calibrated conditions, the opposing force of the spring acting on the shutter. Valves are identified by means of: a model number formed of an alphanumerical code that includes: the family identity (for ex. 3060/45) the type of connection (C = ) the set pressure, expressed in bar, multiplied by 10 (for ex. 300) an alphanumerical serial number. CONSTRUCTION Body: squared, obtained through hot moulding and subsequent machining. It houses the following elements: the nozzle with flat sealing seat the shutter guide the set spring slot the threaded seat of the setting adjustment ring nut In the body, above the shutter guide, a small pressure relief hole is provided through which the spring slot communicates with the exit connection. Material used: EN CW617N brass Shutter: obtained through machining from bar stock and fit with gasket, it ensures the required degree of SCOPE Use: protection against possible overpressure of the apparatuses listed below, with regard to the operating conditions for which they have been designed: Refrigeration system or heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, or piping. (reference standard: EN 378-2:2016) Simple pressure vessels (reference Directive: 2009/105/EC) Fluids: the valves in series 3060 can be used with: a. Refrigerant fluids in vapour or gaseous state belonging to Group 2: HCFC (R22) HFC (R134a, R404A, R407C, R410A, R507) HFO and HFO/HFC mixtures (R1234ze, R448A, R449A, R450A, and R452A) R744 with reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC Regulation No. 1272/2008). b. Air and nitrogen (reference Directive: 2009/105/EC) For specific applications with refrigerant fluids not listed above, please contact Castel Technical Department. DS-ED 01/ ENG 13

14 MARKING In compliance with the provisions of Article 19 of Directive 2014/68/EC, the following information is reported on the valve body: Manufacturer s mark Country of manufacturing Indication of flow direction Maximum allowable pressure CE marking Identification number of the notified body involved in the production control phase Again, on the body, the following information is laser marked: Valve model Serial number Set pressure Kd discharge coefficient Flow section Production date DOCUMENTATION The safety valves in series 3060 are supplied with the following documentation provided in the packaging: operating instructions for the user, containing all information useful for safety in terms of assembly, commissioning, use, and maintenance. Compliance Statement for the equipment according to Directive 2014/68/EU, required in Article 17 and issued in compliance with Annex IV of the same directive. Calibration certificate for the safety valve, printed on the reverse side of the Compliance Statement. N.B.: on the website: use the Certifications pull-down menu to access the web-page Castel Certification Download Center. On this page, you can download: the Compliance Statement / Calibration Certificate for each valve by entering the 7-digit alphanumeric serial number. the general Compliance Statement referring to a specific model of valve 3060 with a specific setting, for ex. 3060/24C250 or 3060/45C420. VALVE SELECTION Directive 2014/68/EC requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the maximum allowable pressure (PS) of the equipment they protect. In any case, a short pressure peak limited to 10% of maximum allowable pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific product and sector standards listed below: EN ISO : 2013: Safety devices for protection against excessive pressure Part 1: Safety valves indicates the general requirements for safety valves regardless of the fluid for which they were designed. EN 378-2:2016: Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation provides a general outline of the protection devices to be used in refrigerating systems and their characteristics (Para ) and the criteria for the selection of the device suitable for the type and size of the system component to be protected (Para ). EN 13136:2013: Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and provides users with the tools for sizing pressure relief devices, among which safety valves. select the safety valves in series 3060, please see Chapter 5 Selection Criteria for Safety Valves in this technical handbook. Tables 7, 8, 9, 10 and 11 provide the maximum discharge capacities of safety valves, models 3060/23-/24, 3060/33-/34, 3060/45, 3060/36 and 3060/46, as a function of various refrigerants and varying P set for the valve, considering T o = Steam saturation temperature at discharge pressure, P o. VALVE INSTALLATION Safety valves type 3060 do NOT guarantee repeatable performance. This means that, after the valves have operated, open/close, the initial setting conditions are NOT maintained. calculate the pressure loss in either the upstream line (between vessel and safety valve) or the downstream line (between safety valve and atmosphere) refer to Chapter 5 Selection Criteria for Safety Valves in this technical handbook. 14 DS-ED 01/ ENG

15 TABLE 5: General Characteristics of valves 3060 Catalogue Number 3060/23C 3060/24C 3060/33C 3060/34C 3060/45C 3060/36C 3060/46C Connections Inlet male 1/4" 1/4" 3/8" 3/8" 1/2" 3/8" 1/2" Outlet male 3/8" SAE 1/2" SAE 3/8" SAE 1/2" SAE 5/8" SAE 3/4" G 3/4" G Inlet connection wrench torque (min/max) [Nm] 10/15 10/15 14/20 14/20 21/30 14/20 21/30 Flow Diameter [mm] 7,0 9,5 10,0 Flow Section [mm2] 38,5 70,9 78,5 Discharge Coefficient "Kd" 0,63 0,69 0,63 0,69 0,45 0,92 0,93 PS [bar] 55 TS - 50 / TA - 40 / + 50 Set Pressure Range at atmospheric back pressure Pset [bar] Overpressure 9 / % of Pset Blowdown - 50 % of Pset - 40 % of Pset Helium tightness Estimated service life Risk Category according to PED Recast 80 % di Pset (9 bar < Pset < 31 bar) 90 % di Pset (31,1 bar < Pset < 50 bar) 5 years IV Catalogue Number TABLE 6: Dimensions and Weights of valves 3060 Dimensions [mm] Ø D L Ch H 1 H 2 H 3 Weight [g] 3060/23C 21, ,5 46, /24C 21, ,5 46, /33C 21, ,5 46, /34C 21, ,5 46, /45C 24,5 39, , /36C ,5 96, /46C ,5 99,5 380 DS-ED 01/ ENG 15

16 Pset [bar] Po [barsass] TABLE 7: Maximum discharge capacity of valves 3060/23 ; 3060/33 R134a R22 R404A R407C R410A R448A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , ,0 45,0 90, , , ,0 46,1 92, , , ,0 47,2 93, , ,0 48,3 94, , ,0 49,4 95, ,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued 16 DS-ED 01/ ENG

17 Pset [bar] Po [barsass] TABLE 7: Maximum discharge capacity of valves 3060/23 ; 3060/33 R449A R450A R452A R507 R1234ze R744 (CO2) 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , , ,0 35,1 71, , , , , , ,0 36,2 73, , , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, , ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 DS-ED 01/ ENG 17

18 Pset [bar] Po [barsass] TABLE 8: Maximum discharge capacity of valves 3060/24 ; 3060/34 R134a R22 R404A R407C R410A R448A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , ,0 45,0 90, , , ,0 46,1 92, , , ,0 47,2 93, , ,0 48,3 94, , ,0 49,4 95, ,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued 18 DS-ED 01/ ENG

19 Pset [bar] Po [barsass] TABLE 8: Maximum discharge capacity of valves 3060/24 ; 3060/34 R449A R450A R452A R507 R1234ze R744 (CO2) 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , , ,0 35,1 71, , , , , , ,0 36,2 73, , , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, , ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 DS-ED 01/ ENG 19

20 Pset [bar] Po [barsass] TABLE 9: Maximum discharge capacity of valves 3060/45 R134a R22 R404A R407C R410A R448A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , ,0 45,0 90, , , ,0 46,1 92, , , ,0 47,2 93, , ,0 48,3 94, , ,0 49,4 95, ,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued 20 DS-ED 01/ ENG

21 Pset [bar] Po [barsass] TABLE 9: Maximum discharge capacity of valves 3060/45 R449A R450A R452A R507 R1234ze R744 (CO2) 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , , ,0 35,1 71, , , , , , ,0 36,2 73, , , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, , ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 DS-ED 01/ ENG 21

22 Pset [bar] Po [barsass] TABLE 10: Maximum discharge capacity of valves 3060/36 R134a R22 R404A R407C R410A R448A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , ,0 45,0 90, , , ,0 46,1 92, , , ,0 47,2 93, , ,0 48,3 94, , ,0 49,4 95, ,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued 22 DS-ED 01/ ENG

23 Pset [bar] Po [barsass] TABLE 10: Maximum discharge capacity of valves 3060/36 R449A R450A R452A R507 R1234ze R744 (CO2) 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , , ,0 35,1 71, , , , , , ,0 36,2 73, , , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, , ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 DS-ED 01/ ENG 23

24 Pset [bar] Po [barsass] TABLE 11: Maximum discharge capacity of valves 3060/46 R134a R22 R404A R407C R410A R448A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , ,0 45,0 90, , , ,0 46,1 92, , , ,0 47,2 93, , ,0 48,3 94, , ,0 49,4 95, ,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued 24 DS-ED 01/ ENG

25 Pset [bar] Po [barsass] TABLE 11: Maximum discharge capacity of valves 3060/46 R449A R450A R452A R507 R1234ze R744 (CO2) 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , , ,0 35,1 71, , , , , , ,0 36,2 73, , , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, , ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 DS-ED 01/ ENG 25

26 CHAPTER 3 SAFETY VALVES IN SERIES 3061 Shutter: obtained through machining from bar stock and fit with gasket, it ensures the required degree of tightness on the valve seat. The gasket is made from modified PTFE (Polytetrafluorethylene), a material that, during the valve s estimated service life, maintains good strength and does not cause the shutter to stick on the seat. The shutter is properly guided in the body and the guide action cannot fail. There are no glands or retaining rings that hamper its movement. Material used: EN CW614N brass Spring: it opposes the pressure and the fluid dynamic forces, and always ensures closing of the valve following pressure relief. When the shutter has reached the maximum height determined by the mechanical stop, the spring compression does not exceed 80% of the total compression. All the springs are compliant with the compression helical spring requirements defined in EN ISO :2013. Material used: EN FD steel for springs. GENERAL DESCRIPTION The valves in series 3061 are unbalanced, conventional direct-loaded safety valves. The valve is opened by the thrust from the fluid under pressure below the shutter, when said thrust exceeds, under the calibrated conditions, the opposing force of the spring acting on the shutter. Valves are identified by means of: a model number formed of an alphanumerical code that includes: the family identity (for ex. 3061/3) the type of inlet connection (for ex. C = ) the set pressure, expressed in bar, multiplied by 10 (for ex. 200) an alphanumerical serial number. CONSTRUCTION Body: squared, obtained through hot moulding and subsequent machining. It houses the following elements: the nozzle with flat sealing seat the shutter guide the set spring slot the threaded seat of the setting adjustment ring nut In the body, above the shutter guide, a small pressure relief hole is provided through which the spring slot communicates with the exit connection. For this reason, during relief, there is a no gas leak through this orifice. Material used: EN CW617N brass Calibration system: hex-head threaded ring nut to be screwed inside the upper portion of the head, compressing the spring below. When calibration is complete, the position of the ring nut is maintained unchanged by applying to the threaded coupling a high mechanical strength and low viscosity bonding agent. The low viscosity promotes penetration. The calibration system is protected against subsequent tampering by means of a threaded cap nut, screwed on outside the brass body and blocked in place through re-flanging. SCOPE Use: protection against possible overpressure of the apparatuses listed below, with regard to the operating conditions for which they have been designed: Refrigeration system or heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, or piping. (reference standard: EN 378-2:2016) Simple pressure vessels (reference Directive: 2009/105/EC) Fluids: the valves in series 3061 can be used with: a. Refrigerant fluids in vapour or gaseous state belonging to Group 2: HCFC (R22) HFC (R134a, R404A, R407C, R410A, R507) HFO and HFO/HFC mixtures (R1234ze, R448A, R449A, R450A, and R452A) R DS-ED 01/ ENG

27 with reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC Regulation No. 1272/2008). b. Refrigerant fluids in vapour or gaseous state belonging to Group 1: HFO (R1234yf) HC (R290, R600, R600a) with reference to Article 13, Para. 1(a) of Directive 2014/68/EU (EC Regulation No. 1272/2008). c. Air and nitrogen (reference Directive: 2009/105/EC) For specific applications with refrigerant fluids not listed above, please contact Castel Technical Department. MARKING In compliance with the provisions of Article 19 of Directive 2014/68/EC, the following information is cast on the valve body: Manufacturer s mark Country of manufacturing Indication of flow direction Maximum allowable pressure Again, on the body, the following information is laser marked: Valve model Serial number Set pressure Allowable temperature range Kd discharge coefficient Flow section Production date CE marking Identification number of the notified body involved in the production control phase DOCUMENTATION The safety valves in series 3061 are supplied with the following documentation provided in the packaging: operating instructions for the user, containing all information useful for safety in terms of assembly, commissioning, use, and maintenance. Compliance Statement for the equipment according to Directive 2014/68/EU, required in Article 17 and issued in compliance with Annex IV of the same directive. Calibration certificate for the safety valve, printed on the reverse side of the Compliance Statement. N.B.: on the website: use the Certifications pull-down menu to access the web-page Castel Certification Download Center. On this page, you can download: the Compliance Statement / Calibration Certificate for each valve by entering the 7-digit alphanumeric serial number. the general Compliance Statement referring to a specific model of valve 3061 with a specific setting, for ex. 3061/2C250 or 3061/4C420. VALVE SELECTION Directive 2014/68/EC requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the maximum allowable pressure (PS) of the equipment they protect. In any case, a short pressure peak limited to 10% of maximum allowable pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific product and sector standards listed below: EN ISO : 2013: Safety devices for protection against excessive pressure Part 1: Safety valves indicates the general requirements for safety valves regardless of the fluid for which they were designed. EN 378-2:2016 Refrigerating systems and heat pumps Safety and environmental requirements Part 2: Design, construction, testing, marking and documentation provides a general outline of the protection devices to be used in refrigerating systems and their characteristics (Para ) and the criteria for the selection of the device suitable for the type and size of the system component to be protected (Para ). EN 13136:2013: Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and provides users with the tools for sizing pressure relief devices, among which safety valves. select the safety valves in series 3061, please see Chapter 5 Selection Criteria for Safety Valves in this technical handbook. Table 14 provides the maximum discharge capacities of safety valves, models 3061/2, 3061/3 and 3061/4, as a function of various refrigerants and varying P set for the valve, considering T o = Steam saturation temperature at discharge pressure, P o. VALVE INSTALLATION Safety valves type 3061 guarantee repeatable performance. This means that, after the valves have operated, open/close, the initial setting conditions are maintained. PNevertheless, it is advisable to replace a 3061 valve once it has discharged as during release debris, such as metal shavings or solder impurities, can deposit on the valve gasket. This can inhibit the safety valve from returning to its original conditions. calculate the pressure loss in either the upstream line (between vessel and safety valve) or the downstream line (between safety valve and atmosphere) refer to Chapter 5 Selection Criteria for Safety Valves in this technical handbook. DS-ED 01/ ENG 27

28 TABLE 12 : General Characteristics of valves 3061 Catalogue Number 3061/2C 3061/3C 3061/4C Connections Inlet male 1/4" 3/8" 1/2" Outlet male 3/8" G 1/2" G 1/2" G Inlet connection wrench torque (min/max) [Nm] 10/15 14/20 21/30 Flow Diameter [mm] 7,5 7,5 7,5 Flow Section [mm2] 44,2 44,2 44,2 Lift [mm] Discharge Coefficient "Kd" 0,89 0,89 0,89 PS [bar] 70 TS - 50 / TA - 40 / + 50 Set Pressure Range at atmospheric back pressure Pset [bar] Overpressure Blowdown Helium tightness Estimated service life Risk Category according to PED Recast 11 / % of Pset - 15 % of Pset - 20 % of Pset (11 bar < Pset < 14 bar) - 15 % of Pset (14,1 bar < Pset < 24 bar) - 10 % of Pset (24,1 bar < Pset < 60 bar) 9 years IV Catalogue Number TABLE 13: Dimensions and Weights of valves 3061 Dimensions [mm] Ø D L Ch H 1 H 2 H 3 Weight [g] 3061/2C 28,5 33, /3C 28,5 33, /4C 28,5 33, DS-ED 01/ ENG

29 Pset [bar] Po [barsass] TABLE 14: Maximum discharge capacity of valves 3061 R134a R22 R32 R404A R407C R410A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , , ,0 45,0 90, , , , ,0 46,1 92, , , , ,0 47,2 93, , , ,0 48,3 94, , , ,0 49,4 95, , ,0 50,5 71, ,0 51,6 72, ,0 52,7 73, ,0 53,8 74, ,0 54,9 75, ,0 56,0 76, ,0 57,1 77, ,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued DS-ED 01/ ENG 29

30 Pset [bar] Po [barsass] TABLE 14: Maximum discharge capacity of valves 3061 R448A R449A R450A R452A R507 R1234yf 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , ,0 35,1 71, , , , , ,0 36,2 73, , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, ,0 45,0 41,0 46,1 42,0 47,2 43,0 48,3 44,0 49,4 45,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 30 DS-ED 01/ ENG

31 Pset [bar] Po [barsass] TABLE 14: Maximum discharge capacity of valves 3061 R1234ze R290 R600 R600a R744 (CO2) 11,0 13,1 61, , , , , ,0 14,2 64, , , , , ,0 15,3 67, , , , , ,0 16,4 70, , , , , ,0 17,5 73, , , , , ,0 18,6 76, , , , , ,0 19,7 79, , , , , ,0 20,8 81, , , , , ,0 21,9 84, , , , , ,0 23,0 86, , , , ,0 24,1 88, , , , ,0 25,2 90, , , , ,0 26,3 93, , , , ,0 27,4 95, , , , ,0 28,5 97, , , , ,0 29,6 98, , , , ,0 30,7 100, , , , ,0 31,8 102, , , , ,0 32,9 104, , , , ,0 34,0 106, , , , ,0 35,1 107, , , , ,0 36,2 109, , , , ,0 37,3 89, , ,0 38,4 91, , ,0 39,5 92, , ,0 40,6 94, , ,0 41,7 95, , ,0 42,8 8, ,0 43,9 9, ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 19, ,0 58,2 20, ,0 59,3 21, ,0 60,4 22, ,0 61,5 23, ,0 62,6 23, ,0 63,7 24, ,0 64,8 25, ,0 65,9 26, ,0 67,0 26, DS-ED 01/ ENG 31

32 CHAPTER 4 SAFETY VALVES IN SERIES 3065 Shutter: obtained through machining from bar stock and fit with gasket, it ensures the required degree of tightness on the valve seat. The gasket is made from modified PTFE (Polytetrafluorethylene), a material that, during the valve s estimated service life, maintains good strength and does not cause the shutter to stick on the seat. The shutter is properly guided in the body and the guide action cannot fail. There are no glands or retaining rings that hamper its movement. Material used: EN CW614N brass Spring: it opposes the pressure and the fluid dynamic forces, and always ensures closing of the valve following pressure relief. When the shutter has reached the maximum height determined by the mechanical stop, the spring compression does not exceed 80% of the total compression. All the springs are compliant with the compression helical spring requirements defined in EN ISO :2013. Material used: EN FD steel for springs. GENERAL DESCRIPTION The valves in series 3065 are unbalanced, conventional direct-loaded safety valves. The valve is opened by the thrust from the fluid under pressure below the shutter, when said thrust exceeds, under the calibrated conditions, the opposing force of the spring acting on the shutter. Valves are identified by means of: a model number formed of an alphanumerical code that includes: the family identity (for ex. 3065/4) the type of inlet connection (for ex. C = ) the set pressure, expressed in bar, multiplied by 10 (for ex. 140) an alphanumerical serial number CONSTRUCTION Body: squared, obtained through hot moulding and subsequent machining. It houses the following elements: the nozzle with flat sealing seat the shutter guide the set spring slot the threaded seat of the setting adjustment ring nut In the body, above the shutter guide, a small pressure relief hole is provided through which the spring slot communicates with the exit connection. For this reason, during relief, there is a no gas leak through this orifice. Material used: EN CW617N brass Calibration system: hex-head threaded ring nut to be screwed inside the upper portion of the head, compressing the spring below. When calibration is complete, the position of the ring nut is maintained unchanged by applying to the threaded coupling a high mechanical strength and low viscosity bonding agent. The low viscosity promotes penetration. The calibration system is protected against subsequent tampering by means of a threaded cap nut, screwed on outside the brass body and blocked in place through re-flanging. SCOPE Use: protection against possible overpressure of the apparatuses listed below, with regard to the operating conditions for which they have been designed: Refrigeration system or heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, or piping (reference standard: EN 378-2:2016) Simple pressure vessels (reference Directive: 2009/105/EC) Fluids: the valves in series 3065 can be used with: a. Refrigerant fluids in vapour or gaseous state belonging to Group 2: HCFC (R22) HFC (R134a, R404A, R407C, R410A, R507) HFO and HFO/HFC mixtures (R1234ze, R448A, R449A, R450A, and R452A) R DS-ED 01/ ENG

33 with reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC Regulation No. 1272/2008). b. Refrigerant fluids in vapour or gaseous state belonging to Group 1: HFC (R32) HFO (R1234yf) HC (R290, R600, R600a) with reference to Article 13, Para. 1(a) of Directive 2014/68/EU (EC Regulation No. 1272/2008). c. Air and nitrogen (reference Directive: 2009/105/EC) For specific applications with refrigerant fluids not listed above, please contact Castel Technical Department. MARKING In compliance with the provisions of Article 19 of Directive 2014/68/EC, the following information is cast on the valve body: Manufacturer s mark Country of manufacturing Indication of flow direction Maximum allowable pressure Again, on the body, the following information is laser marked: Valve model Serial number Set pressure Allowable temperature range Kd discharge coefficient Flow section Production date CE marking Identification number of the notified body involved in the production control phase DOCUMENTATION The safety valves in series 3065 are supplied with the following documentation provided in the packaging: operating instructions for the user, containing all information useful for safety in terms of assembly, commissioning, use, and maintenance. Compliance Statement for the equipment according to Directive 2014/68/EU, required in Article 17 and issued in compliance with Annex IV of the same directive. Calibration certificate for the safety valve, printed on the reverse side of the Compliance Statement. N.B.: on the website: use the Certifications pull-down menu to access the web-page Castel Certification Download Center. On this page, you can download: the Compliance Statement / Calibration Certificate for each valve by entering the 7-digit alphanumeric serial number. the general Compliance Statement referring to a specific model of valve 3065 with a specific setting, for ex. 3065/4C250 or 3065/6C420. VALVE SELECTION Directive 2014/68/EC requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the maximum allowable pressure (PS) of the equipment they protect. In any case, a short pressure peak limited to 10% of maximum allowable pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific product and sector standards listed below: EN ISO : 2013: Safety devices for protection against excessive pressure Part 1: Safety valves indicates the general requirements for safety valves regardless of the fluid for which they were designed. EN 378-2:2016 Refrigerating systems and heat pumps Safety and environmental requirements Part 2: Design, construction, testing, marking and documentation provides a general outline of the protection devices to be used in refrigerating systems and their characteristics (Para ) and the criteria for the selection of the device suitable for the type and size of the system component to be protected (Para ). EN 13136:2013: Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and provides users with the tools for sizing pressure relief devices, among which safety valves. For sizing of the safety valves in series 3065, please see Chapter 5 Selection Criteria for Safety Valves in this technical handbook. Table 17 provides the maximum discharge capacities of safety valves, models 3065/4 and 3065/6, as a function of various refrigerants and varying P set for the valve, considering T o = Steam saturation temperature at discharge pressure, P o. DS-ED 01/ ENG 33

34 TABLE 15 : General Characteristics of valves 3065 Catalogue Number 3065/4C 3065/6C Connections Inlet male 1/2" 3/4" Outlet male 1" G 1" G Inlet connection wrench torque (min/max) [Nm] 21/30 32/45 Flow Diameter [mm] 13,0 13,0 Flow Section [mm2] 132,7 132,7 Lift [mm] 6,3 6,3 Discharge Coefficient "Kd" 0,87 0,87 PS [bar] 70 TS - 50 / TA - 40 / + 50 Set Pressure Range at atmospheric back pressure Pset [bar] Overpressure Blowdown Helium tightness Estimated service life Risk Category according to PED Recast 11 / % of Pset - 15 % of Pset - 20 % of Pset (11 bar < Pset < 14 bar) - 15 % of Pset (14,1 bar < Pset < 24 bar) - 10 % of Pset (24,1 bar < Pset < 60 bar) 9 years IV Catalogue Number TABLE 16: Dimensions and Weights of valves 3065 Dimensions [mm] Ø D L Ch H 1 H 2 H 3 Weight [g] 3065/4C 38, /6C 38, DS-ED 01/ ENG

35 Pset [bar] Po [barsass] TABLE 17: Maximum discharge capacity of valves 3065 R134a R22 R32 R404A R407C R410A 11,0 13,1 49, , , , , , ,0 14,2 53, , , , , , ,0 15,3 56, , , , , , ,0 16,4 58, , , , , , ,0 17,5 61, , , , , , ,0 18,6 64, , , , , , ,0 19,7 66, , , , , , ,0 20,8 69, , , , , , ,0 21,9 71, , , , , , ,0 23,0 73, , , , , , ,0 24,1 75, , , , , , ,0 25,2 77, , , , , , ,0 26,3 79, , , , , , ,0 27,4 81, , , , , , ,0 28,5 83, , , , , , ,0 29,6 85, , , , , , ,0 30,7 87, , , , , , ,0 31,8 89, , , , , , ,0 32,9 90, , , , , , ,0 34,0 92, , , , , , ,0 35,1 93, , , , , , ,0 36,2 95, , , , , , ,0 37,3 96, , , , , , ,0 38,4 98, , , , , ,0 39,5 99, , , , , ,0 40,6 99, , , , , ,0 41,7 99, , , , , ,0 42,8 88, , , , ,0 43,9 89, , , , ,0 45,0 90, , , , ,0 46,1 92, , , , ,0 47,2 93, , , ,0 48,3 94, , , ,0 49,4 95, , ,0 50,5 71, ,0 51,6 72, ,0 52,7 73, ,0 53,8 74, ,0 54,9 75, ,0 56,0 76, ,0 57,1 77, ,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued DS-ED 01/ ENG 35

36 Pset [bar] Po [barsass] TABLE 17: Maximum discharge capacity of valves 3065 R448A R449A R450A R452A R507 R1234yf 11,0 13,1 31, , , , , , ,0 14,2 34, , , , , , ,0 15,3 36, , , , , , ,0 16,4 39, , , , , , ,0 17,5 42, , , , , , ,0 18,6 44, , , , , , ,0 19,7 46, , , , , , ,0 20,8 49, , , , , , ,0 21,9 51, , , , , , ,0 23,0 53, , , , , , ,0 24,1 55, , , , , , ,0 25,2 57, , , , , , ,0 26,3 58, , , , , , ,0 27,4 60, , , , , , ,0 28,5 62, , , , , , ,0 29,6 64, , , , , , ,0 30,7 65, , , , , , ,0 31,8 67, , , , , , ,0 32,9 68, , , , , , ,0 34,0 70, , , , , ,0 35,1 71, , , , , ,0 36,2 73, , , , , ,0 37,3 74, , , ,0 38,4 75, , , ,0 39,5 76, , ,0 40,6 78, , ,0 41,7 79, , ,0 42,8 80, , ,0 43,9 80, ,0 45,0 41,0 46,1 42,0 47,2 43,0 48,3 44,0 49,4 45,0 50,5 46,0 51,6 47,0 52,7 48,0 53,8 49,0 54,9 50,0 56,0 51,0 57,1 52,0 58,2 53,0 59,3 54,0 60,4 55,0 61,5 56,0 62,6 57,0 63,7 58,0 64,8 59,0 65,9 60,0 67,0 Continued 36 DS-ED 01/ ENG

37 Pset [bar] Po [barsass] TABLE 17: Maximum discharge capacity of valves 3065 R1234ze R290 R600 R600a R744 (CO2) 11,0 13,1 61, , , , , ,0 14,2 64, , , , , ,0 15,3 67, , , , , ,0 16,4 70, , , , , ,0 17,5 73, , , , , ,0 18,6 76, , , , , ,0 19,7 79, , , , , ,0 20,8 81, , , , , ,0 21,9 84, , , , , ,0 23,0 86, , , , ,0 24,1 88, , , , ,0 25,2 90, , , , ,0 26,3 93, , , , ,0 27,4 95, , , , ,0 28,5 97, , , , ,0 29,6 98, , , , ,0 30,7 100, , , , ,0 31,8 102, , , , ,0 32,9 104, , , , ,0 34,0 106, , , , ,0 35,1 107, , , , ,0 36,2 109, , , , ,0 37,3 89, , ,0 38,4 91, , ,0 39,5 92, , ,0 40,6 94, , ,0 41,7 95, , ,0 42,8 8, ,0 43,9 9, ,0 45,0 10, ,0 46,1 11, ,0 47,2 11, ,0 48,3 12, ,0 49,4 13, ,0 50,5 14, ,0 51,6 15, ,0 52,7 16, ,0 53,8 17, ,0 54,9 18, ,0 56,0 19, ,0 57,1 19, ,0 58,2 20, ,0 59,3 21, ,0 60,4 22, ,0 61,5 23, ,0 62,6 23, ,0 63,7 24, ,0 64,8 25, ,0 65,9 26, ,0 67,0 26, VALVE INSTALLATION Safety valves type 3065 guarantee repeatable performance. This means that, after the valves have operated, open/close, the initial setting conditions are maintained. Nevertheless, it is advisable to replace a 3065 valve once it has discharged as during release debris, such as metal shavings or solder impurities, can deposit on the valve gasket. This can inhibit the safety valve from returning to its original conditions. calculate the pressure loss in either the upstream line (between vessel and safety valve) or the downstream line (between safety valve and atmosphere) refer to Chapter 5 Selection Criteria for Safety Valves in this technical handbook. DS-ED 01/ ENG 37

38 CHAPTER 5 SELECTION CRITERIA FOR SAFETY VALVES CALCULATION OF THE DISCHARGE CAPACITY (Ref. EN 13136:2013) The evaluation of the minimum required discharge capacity of safety valves is closely linked to the type of system where the equipment protected by the valve is installed, with the causes that may cause the safety valve to open, i.e.: External heat sources (Para EN 13136:2013). The minimum required discharge capacity is determined by the following formula: where: φ = density of heat flow rate, assumed to be 10 [kw/m 2 ] A surf = external surface area of the vessel [m 2 ] h vap = latent heat of vaporization of liquid at p o [kj/kg] Internal heat sources (Para EN 13136:2013). The minimum required discharge capacity is determined by the following formula: where Q h = rate of heat production [KW] Increased pressure caused by a positive displacement compressor (Para EN 13136:2013). The minimum required discharge capacity is determined by the following formula: where: V = theoretical displacement of compressor [m 3 ] n = rotational frequency of compressor [min 1 ] ρ 10 = vapour density of refrigerant, from the saturation curve at a temperature of 10 C [kg/m 3 ]. Table 18 provides the values of ρ 10 for: traditional HCFC and HFC refrigerants most commonly used new HFO and HFC/HFO blend refrigerants natural HC fluids (for R744, the ρ -40 vapour density value for CO 2 is indicated, from the saturation curve at a temperature of -40 C [kg/m 3 ]). η v = volumetric efficiency of the compressor, estimated at suction pressure and discharge pressure equivalent to the safety valve setting. SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR AT CRITICAL FLOW (Ref. EN ISO : 2013 and EN :2013) Critical flow occurs when the back-pressure p b (the pressure existing immediately at the outlet of the valve) is lower than or equal to the critical pressure: k 2 k 1 p b p [bar abs] o k + 1 where: p o = actual relieving pressure, upstream the valve. It s equal to the set pressure plus overpressure; that is, the pressure increase over the set pressure at which the shutter has its total lift [bar abs] k = isentropic exponent of gas or vapour, based on the actual temperature and pressure conditions upstream of the valve during the discharge phase under full glow. If k is unknown or difficult to determine, it is possible to assume: p = 0, 5 [bar abs] critica p o A valve that discharges to the atmosphere, is under in critical flow conditions. The safety valves designed to discharge gas or vapour at critical flow must be sized using the following calculation, shown in Paragraph of the EN 13136:2013 standard. [mm 2 ] where: A c = minimum net cross-section area of the valve orifice [mm 2 ] Q md = minimum required discharge capacity of safety valve K d = certified discharge ratio of safety valve p o = actual pressure upstream of the safety valve during discharge of the entire flow, see definition above. [bar abs] v o = specific volume of gas or vapour at discharge conditions p o and T o, where T o is the fluid temperature at valve inlet, defined by the user or by the designer [m 3 /kg] C = expansion rate as a function of the k coefficient in the isentropic equation calculated with the following formula: 38 DS-ED 01/ ENG

39 for this calculation, the value of k refers to a temperature of 25 C. (Para , EN 13136:2013 standard). Table 18 provides the k and C values for: traditional HCFC and HFC refrigerants most commonly used new HFO and HFC/HFO blend refrigerants natural HC fluids and R744 calculate the flow rate of a safety valve, under specific operating conditions, use the following formula, provided in Para of EN 13136:2013. where: Q m = maximum discharge capacity of safety valve A = net cross-section area of the valve orifice [mm 2 ] This formula was used to calculate the maximum discharge flow of the safety valve shown in: Table 3 and 4 for valves in series 3030 Table 7, 8, 9, 10 and 11 for valves in series 3060 Table 14 for valves in series 3061 Table 17 for valves in series 3065 INSTALLATION OF A SAFETY VALVE (Ref. EN 13136:2013) As far as the installation of safety valves is concerned, remember these basic points: Safety valves must be installed near an area of the system where vapours or gases are present and where there is no fluid turbulence. They must be placed in as close to an upright position as possible, with the inlet connector turned downwards. Vessels joined by piping, of a diameter deemed by the manufacturer and the user to be adequate, without any stop valves between them, may be considered as a single vessel for the installation of a safety valve. The fitting between the valve and the equipment to be protected must be as short as possible. Furthermore, the cross-section of the piping must not be smaller than the valve inlet. In any case, EN 13136:2013 states that the pressure drop between the protected vessel and the safety valve, at discharge capacity, shall not exceed 3% of the setting value, po, including any accessory on the line. The location selected for installation of the safety valve must consider that valve operation involves the discharge of the refrigerant fluid under pressure, sometimes at high temperature. Where there is the risk of causing injuries to people nearby, exhaust piping must be provided, sized so as to not compromise valve operation. EN 13136:2013 states that this piping must not generate, at discharge capacity, a back-pressure exceeding 10% of pressure po, for unbalanced, conventional valves. In the event of multiple valves installed in parallel, it is highly recommended that each valve be fit with a dedicated exhaust line rather than a single manifold for all of the valves. The risk of the latter solution is to create an overpressure in the manifold determined when a valve discharges. This overpressure can modify the operating characteristics of all the other valves installed in parallel. Pressure losses in the upstream line calculate the pressure losses in the upstream line (between vessel and safety valve) refer to Section 7.4 of EN 13136:2013. The upstream pressure loss is given by: where: A c = minimum calculated flow cross-section area [mm 2 ] A in = cross-section area of inlet tube to valve [mm 2 ] K dr = K d x 0.9, reduced discharge coefficient C = expansion rate as a function of the k coefficient in the isentropic equation for the refrigerant fluid ξ = sum of the of pressure loss coefficients ξ n of the individual components and piping. The coefficients ξ n refer to: pipe element losses, such as fittings and elbows valve losses losses along the piping and are listed in standard EN 13136:2013, Table A.4. Pressure losses in the downstream line calculate the pressure losses in the downstream line (between safety valve and atmosphere) refer to Section 7.4 of EN 13136:2013. The downstream pressure loss is given by: where: P 1 = inlet pressure to discharge line [bar abs] P 2 = outlet pressure to discharge line, equal to atmospheric pressure [bar abs] A c = minimum calculated flow cross-section area [mm 2 ] A out = cross-section area of valve outlet pipe [mm 2 ] K dr = K d x 0.9, reduced discharge coefficient DS-ED 01/ ENG 39

40 C = expansion rate as a function of the k coefficient in the isentropic equation for the refrigerant fluid p o = actual pressure downstream of the safety valve during discharge of the entire flow [bar abs] ξ = sum of the of pressure loss coefficients ξ n of the piping The coefficients ξ n refer to: pipe element losses, bends losses along the piping e sono elencati nella Tabella A.4 della norma EN 13136:2013. EXAMPLE 1: Calculation of the flow rate (Q md ) and selection of the safety valve (Increased pressure caused by a positive displacement compressor) Compressor data Bore: 82.5 mm Stroke: 69.8 mm Number of cylinders 4 Rotational frequency 1450 rpm Clearance 4% Refrigerant fluid R407C The theoretical displacement of the compressor is: [m 3 ] Maximum allowable pressure of the liquid condenser / receiver: PS = 25 bar Set pressure of the safety valve installed on the upper crown of the condenser housing: p set = 25 bar Calculation of the valve discharge pressure under full flow exhaust conditions: using a safety valve in series 3065 with an overpressure of 10%: [bar abs] Operating conditions of compressor at the safety valve discharge: Condensation temperature: C (28.5 bar abs) Evaporation temperature: +10 C (6.33 bar abs) These conditions, defined by the designer, are assumed to be the most unfavourable for the safety valve due to operating faults such as: Movement errors Non-operation of automatic safety devices that should have been triggered prior to the safety valve due to failures or other reasons Calculation of minimum full discharge capacity For cautionary reasons, ignoring the vapour overheating at the outlet of the evaporator, the volumetric efficiency of compressor is: and so the minimum required full discharge capacity: where ρ 10 = [kg/m 3 ], saturated vapour density of R407C at a temperature of 10 C Sizing of minimum flow cross-section area of the safety valve 0,87 80,3 [mm 2 ] where: C = 2.51, corresponding to k exponent for R407C, equal to 1.14, according to Table 1 K d = 0.87, certified discharge ratio of safety valve 3065/4 v o = [m 3 /kg], specific volume of the saturated vapour upstream of the safety valve during operation. This value refers to the following operating conditions upstream of the valve: Pressure p o = 28.5 [bar abs] Temperature T o = 65.2 Conclusion: the selected safety valve is model 3065/4 with the following characteristics: certified discharge ratio, K d = 0.87 nozzle cross-section area, A = [mm 2 ] set pressure, p set = 25 bar Verification of the system upstream the safety valve Assuming the valve installed is 3065/4C250, using a steel fitting with the following characteristics: d in = 17 [mm], fitting inside diameter A in = 227 [mm 2 ], fitting inside cross-section area L = 60 [mm], fitting length Condenser connection: Flush with the housing and with a sharp edge The following information is taken from Table A.4 in standard EN 13136:2013: ξ 1 (inlet) = 0.25 ξ 2 (length) = λ x L/ din = 0.02 x 60/17 = 0.07 with λ = 0.02 for steel pipe ξ T = ξ 1 + ξ 2 = = 0.32 Between the safety valve and the steel fitting, a shut-off valve type 3064/44 is installed. The main characteristics of this valve are: d R = 13 [mm], inside valve diameter A R = [mm 2 ], inside valve cross-section area kv = 10 [m 3 /h], valve kv coefficient The pressure loss coefficient ξ R of the shut-off valve is given by: tal loss coefficient: ξ T + ξ R = DS-ED 01/ ENG

41 Recalling the previously calculated cross-section, the characteristics of safety valve 3065/4 and refrigerant fluid R407C: A c = 80.3 [mm 2 ] K dr = 0.87 x 0.9 =0.783 C = 2.51 The pressure loss is given by: 80,3 The pressure loss value obtained is admissible because it is lower than the value of 0.03 indicated in standard EN 13136:2013. Verification of system downstream the safety valve Suppose it is necessary to construct a discharge pipe on safety valve 3065/4C250, using 1 gas pipe with the following characteristics: d out = 30 [mm], inside pipe diameter A out = 707 [mm 2 ], inside pipe cross-section area L = 3000 [mm], pipe length 90 elbow with bending radius, R, equal to three times external diameter of pipe The following information is taken from Table A.4 in standard EN 13136:2013: ξ 1 (elbow) = 0.25 ξ 2 (length) = λ x L/ d out = 0.02 x 3000/30 = 2 where λ = 0.02 for steel pipe ξ T = ξ 1 + ξ 2 = = 2.25 The pressure loss is given by: 80,3 [bar] 0,783 0,783 The pressure loss value obtained is admissible because it is lower than the value of 0.10 indicated in standard EN 13136:2013. N.B.: All steps performed in the previous example, that is: calculation of minimum discharge capacity sizing of minimum cross-sectional area of the valve orifice calculation of the load loss in the upstream system calculation of the load loss in the downstream system can be performed using the selection software available on the Castel website. EXAMPLE 2: Calculation of the flow rate (Q md ) and selection of the safety valve (Increase in pressure caused by internal heat source) Data for the liquid receiver Refrigerant fluid R404A Pressure equipment 300 l liquid receiver External surface area of the vessel 3.2 m 2 PS of the vessel 28 bar Calculation of the valve discharge pressure under full flow exhaust conditions: using a safety valve in series 3061 with an overpressure of 10%: [bar abs] Calculation of minimum discharge capacity Calculation of the flow rate for the external heat source considering that there are flammable substances in such quantities as to feed a fire near the vessel to be protected. where: φ = density of heat flow rate, assumed to be 10 [kw/m 2 ] A surf = external surface area of the vessel [m 2 ] h vap = latent heat of vaporization of R404A at pressure p o [kj/kg] Sizing of minimum flow cross-section area of the safety valve The safety valves to discharge gas or vapour at critical flow must be sized using the following formula. [mm 2 ] where: A c = minimum net cross-section area of the valve orifice [mm 2 ] Q md = minimum required discharge capacity of safety valve C = expansion rate as a function of the k coefficient in the isentropic equation for the R404A refrigerant fluid K d = certified discharge ratio of safety valve 3061/4 p o = pressure downstream of the valve during operation [bar abs] v o = specific volume of the saturated vapour upstream of the safety valve during operation. This value refers to the following operating conditions upstream of the valve: Pressure p o = 31.8 [bar abs] Temperature T o = 64.7 (saturation temperature) Conclusion: the selected safety valve is model 3061/4 with the following characteristics: certified discharge ratio, K d = 0.89 nozzle cross-section area, A = 44.2 [mm 2 ] set pressure, p set = 28 bar of standard EN 13136:2013. Verification of the system upstream the safety valve Assuming the valve installed is 3061/4C280, using a steel fitting with the following characteristics: DS-ED 01/ ENG 41

42 d in = 17 [mm], fitting inside diameter A in = 227 [mm 2 ], fitting inside cross-section area L = 60 [mm], fitting length Receiver connection: Flush with the housing and with a sharp edge The following data is taken from Table A.4: ξ 1 (inlet) = 0.25 ξ 2 (length) = λ x L/ d in = 0.02 x 60/17 = 0.07 with λ = 0.02 for steel pipe ξ T = ξ 1 + ξ 2 = = 0.32 Between the valve and the fitting, an exchange valve (type 3032/44) has been installed. The main characteristics of this valve are: d R = 13 [mm], inside valve diameter A R = [mm 2 ], inside valve cross-section area kv = 3.3 [m 3 /h], valve kv coefficient The pressure loss coefficient ξ R of the exchange valve is given by: tal loss coefficient: ξ T + ξ R = 4.51 Recalling the previously calculated cross-section, the characteristics of safety valve 3061/4 and refrigerant fluid R404A: A c = 34.2 [mm 2 ] K dr = 0.89 x 0.9 =0.801 C = 2.50 The pressure loss is given by: The pressure loss value obtained is admissible because it is lower than the value of 0.03 indicated in standard EN 13136:2013. Group PED TABLE 18 : Exponent K of the isoentropic equation. Expansion coefficient C. Vapour density ϱ R134a R22 R32 R404A R407C R410A R448A R449A R450A R452A R507 R1234yf R1234ze R290 R600 R600a R k 1,12 1,17 1,24 1,12 1,14 1,17 1,14 1,14 1,11 1,11 1,10 1,07 1,07 1,19 1,10 1,10 1,30 C 2,50 2,54 2,59 2,50 2,51 2,54 2,51 2,51 2,49 2,49 2,48 2,45 2,45 2,55 2,48 2,48 2,63 ϱ [kg/m 3 ] (1) 20,23 28,82 30,23 41,66 27,45 41,92 30,63 31,11 18,49 40,62 44,03 24,27 16,45 13,78 3,87 5,87 26,12 (1) ϱ 10 [kg/m 3 ] for all refrigerant, excluded R744 ϱ -40 [kg/m 3 ] for R DS-ED 01/ ENG

43 CHAPTER 6 CHANGEOVER VALVES IN SERIES 3032, 3032N, AND 3032E APPLICATIONS Changeover valves in series 3032, 3032N and 3032E perform the role of a service valve for a pair of safety valves, allowing the use of one and the exclusion of the other. This device allows the user to work on the isolated valve, for periodic inspection or replacement, while the line is completely operative and the system safety is integral. N.B.: each safety valve located on the changeover valve must have sufficient capacity to protect the vessel alone. Valves models 3032/33, 3032N/33 and 3032E/33 are supplied with: Two female 3/8 threaded connections with swivel nut, Castel code 3039/3 Two O-Rings for these connections These components ensure perfect alignment of a pair of safety valves 3060/33, 3060/34, 3060/36 or 3061/3. Valves models 3032/44, 3032N/44 and 3032E/44 are supplied with: Two female 1/2 threaded connections with swivel nut, Castel code 3039/4 Two O-Rings for these connections These components ensure perfect alignment of a pair of safety valves 3060/45, 46/46 or 3061/4. Valves, models: 3032/64, 3032N/64, and 3032E/64; 3032/66, 3032N/66, and 3032E/66; 3032/88, 3032N/88, and 3032E/88; and 3032/108, 3032N/108, and 3032E/108 do not have threaded connections with swivel nuts on the outlet connection. Therefore, valve models 3030/44, 3030/66, 3030/88, 3065/4 and 3065/6 are screwed directly on to the changeover valve. The valves in this chapter can be used with the same fluids foreseen for safety valves series 3030, 3060, 3061 and 3065, specifically: a. Valves in series 3032 can be used with the following refrigerant fluids: HCFC (R22) HFC (R134a, R32, R404A, R407C, R410A or R507) HFO and HFO/HFC mixtures (R1234yf, R1234ze, R448A, R449A, R450A or R452A) b. Valves in series 3032N can be used with the following refrigerant fluids: HFC (R134a, R32, R404A, R407C, R410A or R507) HFO and HFO/HFC mixtures (R1234yf, R1234ze, R448A, R449A, R450A or R452A) HC (R290, R600, R600a) CAUTION! Valves in series 3032N cannot be installed on systems that use HCFC (R22) refrigerants or other refrigerants blended with mineral oils or alkylbenzenes. c. Valves in series 3032E can be used only with refrigerant fluid R744. CONSTRUCTION Valves in series 3032, 3032N and 3032E are designed so that it is never possible to exclude both safety valves simultaneously. Under working conditions, the shutter must be clamped against one of the two seats of the valve, front port or back port, in order to ensure always full discharge to the corresponding safety valve. Intermediate shutter positions must be avoided in order not to affect the operation of both safety valves. The valve ensures a pressure drop perfectly compatible with the safety valve operation under saturated vapour and superheated vapour discharge conditions. The main parts of the valves in series 3032, 3032N, and 3032E are made from the following materials: Hot forged brass EN CW 617N for the body Steel, with proper surface protection, for the spindle. Chloroprene rubber (CR) for outlet seal gaskets in valves series 3032 Hydrogenated nitrile butadiene rubber (HNBR) for outlet seal gaskets in valves series 3032N Ethylene propylene diene monomer rubber (EPDM) for outlet seal gaskets in valves series 3032E Glass reinforced PBT for the protective cap that covers the spindle. Hot forged steel EN CW 617N for the protective cap of the spindle for models from 1 to 1-1/4. DS-ED 01/ ENG 43

44 GASKET 44 DS-ED 01/ ENG

45 Catalogue Number Designed for valve TABLE 19: General characteristics, dimensions and weights of valves 3032 Kv Factor [m 3 /h] PS [bar] TS TA Dimensions [mm] min max min max D A B H1 H2 L1 L2 L3 Inlet connection wrench torque (min/max) [Nm] Weight [g] Risk Category according to PED Recast 3032/ /33C 3060/34C 3060/36C 2, /3C /45C 3032/ /46C 3, /4C 3032/ /44C 9,0 3065/4C 17,5 3032/ /66C 9,0 3065/6C ,5 3032/88 14,5 22,0 3030/88C 3032/108 20,0 31,0 3/8" 1/2" 3/4" 3/4" 1" 1. 1/4 3/8" 1/2" 1/2" 3/4" 1" / / / / / / Art. 4.3 Catalogue Number Designed for valve TABLE 20: General characteristics, dimensions and weights of valves 3032N Kv Factor [m 3 /h] PS [bar] TS TA Dimensions [mm] min max min max D A B H1 H2 L1 L2 L3 Inlet connection wrench torque (min/max) [Nm] Weight [g] Risk Category according to PED Recast 3032N/ /33C 3060/34C 3060/36C 3061/3C 2,5 13 3/8" 3/8" / N/ N/ N/ /45C 3060/46C 3061/4C 3030/44C 3065/4C 3030/66C 3065/6C 3, ,0 17,5 9,0 17,5 1/2" 3/4" 3/4" 1/2" 1/2" 3/4" / / / Art. 4.3 Catalogue Number Designed for valve TABLE 21: General characteristics, dimensions and weights of valves 3032E Kv Factor [m 3 /h] PS [bar] TS TA Dimensions [mm] min max min max D A B H1 H2 L1 L2 L3 Inlet connection wrench torque (min/max) [Nm] Weight [g] Risk Category according to PED Recast 3032E/ /33C 3060/34C 3060/36C 3061/3C 2,5 13 3/8" 3/8" / /45C 3032E/ /46C 3, /4C 3032E/ /44C 9,0 3065/4C 17,5 3032E/ /66C 3065/6C 9,0 17,5 3032E/88 14,5 22,0 3030/88C 3032E/108 20,0 31,0 1/2" 3/4" 3/4" 1" 1. 1/4 1/2" 1/2" 3/4" 1" / / / / / Art. 4.3 DS-ED 01/ ENG 45

46 CHAPTER 7 FITTINGS IN SERIES 3035 Copper pipe The fittings in series 3035 allow for the installation of: safety valves in series 3030, 3060, 3061 and 3065 bursting disc devices in series 3070 shut-off valves in series 3064, 3064N and 3064E changeover valves in series 3032, 3032N and 3032E near pressure equipment to be protected in the system. These fittings are designed to be installed in two ways: Construct a copper pipe by-pass that connects the pressure equipment to the fitting. Insert the end of the by-pass in the solder connection of the fitting and then perform capillary brazing. Drill the inner/outer pipe near the pressure equipment (if possible, it is best to build a collar on the pipe). Put the end of the fitting into this hole and proceed to braze weld. The fittings in series 3035 are produced by machining brass bars EN CW614N. Catalogue Number TABLE 22: General characteristics, dimensions and weights of unions 3035 Connections ODS Ø [mm] PS [bar] Dimensions [mm] D L Ch Weight [g] 3035/2 1/ /3 3/ , ,5 3035/4 1/ /6 3/ / /10 1.1/4" DS-ED 01/ ENG

47 CHAPTER 8 SHUT-OFF VALVES IN SERIES 3064, 3064N, AND 3064E a. Valves in series 3064 can be used with the following refrigerant fluids: HCFC (R22) HFC (R134a, R32, R404A, R407C, R410A or R507) HFO and HFO/HFC mixtures (R1234yf, R1234ze, R448A, R449A, R450A or R452A) b. Valves in series 3064N can be used with the following refrigerant fluids: HFC (R134a, R32, R404A, R407C, R410A or R507) HFO and HFO/HFC mixtures (R1234yf, R1234ze, R448A, R449A, R450A or R452A) HC (R290, R600, R600a) CAUTION! Valves in series 3064N cannot be installed on systems that use HCFC (R22) refrigerants or other refrigerants blended with mineral oils or alkylbenzenes. c. Valves in series 3064E can be used only with refrigerant fluid R744. APPLICATIONS Please remember that the operation of pressure equipment and pressure assemblies is not covered by Directive 2014/68/EC ; rather, it is regulated by the national legislation of the Member States of the European Union. Therefore, the various Member States have issued laws that call for periodic inspection of pressure equipment and pressure assemblies. Italy issued Ministerial Decree 329 dated 01/12/2004 regarding the provisions for the installation and use of pressure equipment and pressure assemblies that comply with Directive 97/23/EC. Any intervention for periodic inspection or replacement of an installed safety device becomes very difficult if the protected vessel is not equipped with a shut-off valve. Shut-off valves in series 3064, 3064N and 3064E installed between the protected vessel and the safety valve, allow the device to be disassembled for inspection or replacement without blowing off all the refrigerant fluid from an entire section of the system. The valves in this chapter can be used with the same fluids foreseen for safety valves series 3030, 3060, 3061 and 3065, specifically: CONSTRUCTION Valves in series 3064, 3064N and 3064E are supplied by Castel in the open position and the spindle cap protection is sealed with a Castel lead seal. Any operation to close the valve requires causes the tampering with the seal and must be performed exclusively by: staff authorized to work on the system an operator of a competent inspection body These persons will be responsible for the subsequent re-opening of the valve and the application of a new cap seal with their own lead seal. The main parts of the valves in series 3064, 3064N, and 3064E are made from the following materials: Hot forged brass EN CW 617N for the body Hot forged brass EN CW 617N, chromium plated, for the ball Steel, with proper surface protection, for the spindle. P.T.F.E. for the ball seat gaskets Chloroprene rubber (CR) for outlet seal gaskets in valves series 3064 Hydrogenated nitrile butadiene rubber (HNBR) for outlet seal gaskets in valves series 3064N Ethylene propylene diene monomer rubber (EPDM) for outlet seal gaskets in valves series 3064E Hot forged brass EN CW 617N for the protective cap of the spindle DS-ED 01/ ENG 47

48 SEAL VALVE 3030/.. VALVE 3060/.. BALL VALVE 3064/.. BALL VALVE 3064/.. SEAL SEAL VALVE 3065/.. VALVE 3061/.. BALL VALVE 3064/.. BALL VALVE 3064/.. SEAL SEAL 48 DS-ED 01/ ENG

49 TABLE 23: General characteristics, dimensions and weights of valves series 3064 Catalogue Number Designed for valve Kv Factor [m 3 /h] PS [bar] TS TA Dimensions [mm] Inlet connection wrench min max min max Ø D A C L H torque 1 H 2 H 3 (min/max) [Nm] 3064/ /23C 1/4" /24C 2, /2C / /33C /34C 3/8" 3064/ / /36C /3C /45C / /46C 176 1/2" 3061/4C /4C / /44C / /88C " / Weight [g] Risk Category according to PED Recast Art. 4.3 Catalogue Number 3064N/ N/ N/44 TABLE 24: General characteristics, dimensions and weights of valves series 3064N Designed for valve Kv Factor [m 3 /h] PS [bar] TS TA Dimensions [mm] Inlet connection wrench min max min max Ø D A C L H torque 1 H 2 H 3 (min/max) [Nm] 3060/23C 1/4" /24C 2, /2C /33C /34C 3/8" /36C /3C /45C /46C 176 1/2" 3061/4C /4C /44C 235 Weight [g] 10/ / / Risk Category according to PED Recast Art. 4.3 TABLE 25: General Characteristics, dimensions and weights of valves series 3064E Catalogue Number Designed for valve Kv Factor [m 3 /h] PS [bar] TS TA Dimensions [mm] Inlet connection wrench min max min max Ø D A C L H torque 1 H 2 H 3 (min/max) [Nm] 3064E/ /23C 1/4" /24C 2, /2C / E/ /33C /34C 3/8" /36C /3C / /45C E/ /46C 176 1/2" 3061/4C /4C / /44C E/ /88C " / Weight [g] Risk Category according to PED Recast Art. 4.3 DS-ED 01/ ENG 49

50 CHAPTER 9 BURSTING DISC DEVICES IN SERIES 3070 SCOPE Use: protection against possible overpressure of the apparatuses listed below, with regard to the operating conditions for which they have been designed: Refrigeration system or heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, or piping. (reference standard: EN 378-2:2016) Fluids: the bursting disc devices in series 3070 can be used with: a. Refrigerant fluids in liquid or gaseous state belonging to Group 2: HCFC (R22) HFC (R134a, R404A, R407C, R410A, R507) HFO and HFO/HFC mixtures (R1234ze, R448A, R449A, R450A, and R452A) R744 with reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC Regulation No. 1272/2008). b. Air and nitrogen (reference Directive: 2009/105/EC) GENERAL DESCRIPTION Safety device 3070 is a pressure relief device that cannot be closed again, in which a bursting disc is sensitive to a positive differential pressure between the upstream and downstream sections. It is designed to burst at a specified pressure. Bursting discs in series 3070 are identified by means of: a model number formed of an alphanumerical code that includes: the family identity (for ex. 3070/44C) the type of connection (C = ) the burst pressure, expressed in bar, multiplied by 10 (for ex. 140) a serial number for the lot production. CONSTRUCTION Bursting disc holder: this is the body of the device; it is manufactured in two halves, screwed together, that hold the burst disc in position. The two body halves are obtained through bar machining. The lower half of the body houses the inlet connection, while the upper half houses the outlet connection and two 1/8 female service ports. Material used: EN CW614N brass Bursting discs: the discs are designed and tested, according to the requirements of EN ISO :2003, to burst at a pre-defined pressure. This pressure is called specified burst pressure, and is related to an associated temperature and a burst tolerance. The disc is manufactured from a calibrated gauge of nickel sheet, contained by a copper ring case. The bursting disc devices in series 3070, which can only be used in combination with safety valves in series 3061 or 3065, can be used with: c. Refrigerant fluids in liquid or gaseous state belonging to Group 1: HFC (R32) HFO (R1234yf) HC (R290, R600, R600a) with reference to Article 13, Para. 1(a) of Directive 2014/68/EU (EC Regulation No. 1272/2008). For specific applications with refrigerant fluids not listed above, please contact Castel Technical Department. MARKING In compliance with the provisions of Article 19 of Directive 2014/68/EC, the following information is reported on the bursting disc holder: Manufacturer s mark CE marking Identification number of the notified body involved in the production control phase device model Flow section Indication of flow direction Bursting pressure Performance tolerances Temperature associated with bursting pressure Production date Lot number 50 DS-ED 01/ ENG

51 DOCUMENTATION The bursting disc devices in series 3070 are supplied with the following documents, provided in the packaging: operating instructions for the user, containing all information useful for safety in terms of assembly, commissioning, use, and maintenance. Compliance Statement for the equipment according to Directive 2014/68/EU, required in Article 17 and issued in compliance with Annex IV of the same directive. BURSTING DISC DEVICES SELECTION Directive 2014/68/EU requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as bursting disc devices. Such devices shall prevent pressure from permanently exceeding the maximum allowable pressure (PS) of the equipment they protect. In any case, a short pressure peak limited to 10% of maximum allowable pressure is permitted. The bursting disc safety device 3070 may be used either as sole pressure relief device or in conjunction with a Castel safety valve (types 3030, 3060, 3061, or 3065). The disc and valve combination prevents refrigerant leakage through the safety valve and the total loss of refrigerant after bursting. The disc and valve combination can be also equipped with a suitable pressure switch to detect if the valve has discharged. The bursting pressure of a bursting disc is affected by the operating temperature of fluid contained in the equipment to be protected. The specified bursting pressure (Pb), stamped on the body of the bursting disc, is the nominal bursting pressure at the associated temperature of 22 C. At higher operating temperatures, the nominal bursting pressure is reduced while at lower operating temperatures, the nominal bursting pressure is increased. Refer to table 6 for temperature adjustment factors for Pb. As to the selection and sizing of the suitable protection device, users shall refer to the specific product and sector standards listed below: Standard EN ISO : 2003: Safety devices for protection against excessive pressure Part 2: Bursting disc safety devices specifies the design, manufacturing, inspection, testing, certification, marking and packaging requirements for bursting disc safety devices. EN ISO :2006 Safety devices for protection against excessive pressure Part 3: Safety valves and bursting disc safety devices in combination specifies the general requirements for design, application and marking for a product assembled from the in-series combination of a safety valve and bursting disc safety device. EN ISO : 2003: Safety devices for protection against excessive pressure Part 6: Application, selection and installation of bursting disc safety devices gives guidance on the application, selection and installation of bursting disc safety devices used to protect against overpressure. EN 378-2:2016: Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation provides a general outline of the protection devices to be used in refrigerating systems and their characteristics (Para ) and the criteria for the selection of the device suitable for the type and size of the system component to be protected (Para ). EN 13136:2013: Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and provides users with the tools for sizing pressure relief devices, among which safety valves. SIZING OF BURSTING DISC DEVICES DESIGNED TO DISCHARGE GAS OR VAPOUR AT CRITICAL FLOW (Ref. EN ISO :2003) A bursting disc safety device which discharges to atmosphere works at critical flow. For the definition of critical flow, please see Chapter 5. Bursting disc devices designed to discharge gas or vapour at critical flow must be sized according to the following formula: [mm 2 ] where: A c = minimum cross-section area of the bursting disc [mm 2 ] Q md = minimum required discharge flow rate of the bursting disc α = bursting disc coefficient of discharge p o = bursting pressure [bar abs] v o = specific volume of gas or vapour at discharge conditions p o and T o, where T o is the fluid temperature at bursting disc inlet, defined by the user or by the designer [m 3 /kg] C = expansion rate as a function of the k coefficient in the isentropic equation T o calculate C and to find the values of k and C for the more common refrigerants, see Chapter 5. EN ISO :2003 establishes different values for the coefficient of discharge, α, depending on the nozzle entry configuration where the bursting disc is mounted. The following cases are demonstrated in the aforesaid Standard, Par. C.2.2.1: In case of an internally protruding branch/nozzle: α = 0.68 In case of a flush branch/nozzle whose inlets are not of hydrodynamic configuration: α = 0.73 In case of a flush branch/nozzle with rounded or chamfered inlets: α = 0.80 DS-ED 01/ ENG 51

52 The evaluation of the minimum required discharge capacity of the bursting disc device is closely linked to the type of system where the equipment it protects is installed, with the causes that may cause it to burst, i.e.: external heat sources internal heat sources increased pressure caused by a positive displacement compressor For the calculation of minimum required discharge capacity in these three cases see Chapter 5 Selection Criteria for Safety Valves in this technical handbook. SIZING OF COMBINED DESIGNED TO DISCHARGE GAS OR VAPOUR AT CRITICAL FLOW (Ref. EN ISO :2006) A combination is an installation which includes a bursting disc safety device installed at most five pipe diameters before the inlet of a safety valve. The combination of a specific safety valve with a bursting disc device is characterized by a combination discharge capacity coefficient F d. According to EN ISO : 2006, this coefficient is the ratio of the average of the discharge coefficients ( K d ) of the combination, measured in test bench flow rate tests, to the certified discharge coefficient ( K d ) of the safety valve alone. The same standard also permits, as an alternative to the tests to determine K d of the group, the use of a predefined discharge coefficient ( F d ), equal to 0.9, a slightly lower value than that which could be obtained from testing. Therefore, to size the combination of a safety valve ( , 3061 or 3065) with a bursting disc safety device (3070), please follow the procedure provided in Chapter 5, but multiply the certified coefficient of discharge ( K d ) by 0.9. INSTALLATION OF BURSTING DISC DEVICES AND COMBINATIONS Bursting disc safety device 3070 must never be subjected to a negative pressure differential upstream and downstream of the disc (for example: discharge to the atmosphere and pressure inside the equipment to be protected lower than that of the atmospheric pressure) to avoid damaging or breaking the disk. For this reason, safety device 3070 must always be used along with a cut-off device (such as valve 3064/44) which can exclude device 3070 any time there is a vacuum in the equipment to be protected. When the bursting disc discharges it is necessary to replace the entire unit, as safety devices 3070 are sealed components and the bursting disc cannot be replaced. The maximum operating pressure of the equipment to be protected must not be greater than 75 % of the burst pressure of device 3070 to avoid damages to the disc or leakage. If the operating pressure exceeds 85 % of the burst pressure, safety device 3070 must be replaced immediately. As far as the installation of bursting disc safety devices and combined devices is concerned, remember these basic points: Safety devices must be installed in an area of the system where vapours or gases are present and there is no fluid turbulence. Vessels joined by piping, of a diameter deemed by the manufacturer and the user to be adequate, without any stop valves between them, may be considered as a single vessel for the installation of a safety device. The fitting between the combined device and the equipment to be protected must be as short as possible. Furthermore, the cross-section of the piping must not be smaller than the valve inlet. In any case, EN 13136:2013 states that the pressure drop between the protected vessel and the combined device, at discharge capacity, shall not exceed 3% of the pressure setting value, including any accessories in the line. The location selected for installation of the safety device must consider that its operation involves the discharge of the refrigerant fluid under pressure, sometimes at high temperature. Where there is the risk of causing injuries to people nearby, exhaust piping must be provided, sized so as to not compromise the operation of the device. When installing combined devices, EN 13136:2013 requires that this piping must not generate, at discharge capacity, a back-pressure exceeding 10% of the valve setting pressure. In the event of multiple valves installed in parallel, it is highly recommended that each valve be fit with a dedicated exhaust line rather than a single manifold for all of the valves. The risk of the latter solution is to create an overpressure in the manifold determined when a valve discharges. This overpressure can modify the operating characteristics of all the other valves installed in parallel. calculate the pressure loss in either the upstream line (between vessel and safety device) or the downstream line (between safety device and atmosphere) refer to Chapter 5 Selection Criteria for Safety Valves in this technical handbook. 52 DS-ED 01/ ENG

53 TABLE 26: General characteristics of rupture discs 3070 Catalogue Number 3070/44 Connections Inlet male Outlet female Service 1/2" 1/2" 2 x 1/8" Inlet connection wrench torque (min/max) [Nm] 21/30 Flow Diameter [mm] 12 Flow Section [mm 2 ] 113 TS - 50 / TA - 40 / ,0 15,0 16,0 19,0 21,0 24,0 Bursting Pressure Pb [bar] 24,8 25,0 27,0 27,5 28,0 44 Pb tolerance from 14 up to 19 bar +/- 15 % from 21 up to 44 bar +/- 10% Coincident temperature Ta C 1,13-35 C 1,12-25 C 1,10-10 C 1,03-0 C 1,03 Correction factor of Pb for Ta 22 C 22 C 1,00 40 C 0,99 60 C 0,97 80 C 0, C 0, C 0,93 Max operating pressure 75 % Pb Risk Category according to PED Recast IV DS-ED 01/ ENG 53

54 CHAPTER 10 FUSIBLE PLUGS IN SERIES 3080 AND 3082 conditions for which they have been designed, caused by an excessive external heat source, such as fire. (Para of EN 378-2:2016) Fluids: fusible plugs in series 3080 and 3082 can be used with Group 2 refrigerant fluids in either the gaseous or vapour state: HCFC (R22) HFC (R134a, R404A, R407C, R410A, R507) HFO and HFO/HFC mixtures (R1234ze, R448A, R449A, R450A, and R452A) with reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC Regulation No. 1272/2008). MARKING In compliance with the provisions of Article 19 of Directive 2014/68/EU and of Para of EN 378-2:2016, the following data are reported on the hex nut of fusible plug: CE marking Castel logo Maximum allowable pressure, PS Melting point GENERAL DESCRIPTION According to the definition given in Para of EN 378-1:2016, a fusible plug is a device containing material that melts at a predetermined temperature, thereby relieving the pressure. Castel has decided to classify the fusible plugs in series 3080/.C and 3082/.C in the Risk Category I. This determines their use, as protection devices, on specific pressure equipment, in the same Risk Category I, in compliance with Annex II, Point 2, of Directive 2014/68/EU. Consequently, fusible plugs in series 3080/.C and 3082/.C cannot be used, as sole protection devices, on pressure equipment in Risk Categories greater than I. CONSTRUCTION The body of the fusible plug is an threaded plug drilled with a through hole, with the taper opposite that of the thread. This hole is filled with a specific amount of fusible alloy, with known melting point. Materials used: EN CW 614N lead-free hot tinned brass for the plug Cadmium-free eutectic alloy with several components for the fusible material SCOPE Use: fusible plugs are basically used to protect the components in a refrigerating system or heat pump against possible overpressure, based on the operating INSTALLATION If a fusible plug is mounted on a pressure vessel, it must be installed in a position in which the refrigerant in the superheated gaseous state does not compromise proper operation. Fusible plugs must never be covered by thermal insulation. Discharge from fusible plugs shall take place so that persons and property are not endangered by the released refrigerant. (Para of EN 378-2:2016). EN 378-2:2016 establishes that a fusible plug cannot be used as pressure relief device on vessels containing refrigerants in Groups A2, B1, B2, A3 or B3. The same standard establishes that a fusible plug cannot be used as the sole pressure relief device between a refrigerant containing vessel and the atmosphere in systems with a refrigerant charge greater than 2.5 kg of Group A1 refrigerants (for ex. R22, R134a, R404A, R407C, R410A. R507). FUSIBLE PLUG SELECTION Directive 2014/68/EU requires that pressure equipment, in which it is reasonably possible to forecast that the admissible limits will be exceeded, shall be fit with suitable protection devices, for instance safety devices such as fusible plugs. Such devices shall prevent pressure from permanently exceeding the maximum allowable pressure (PS) of the equipment they protect. In any case, a short pressure peak limited to 10% of maximum allowable pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific product and sector standards. 54 DS-ED 01/ ENG